Questionnaire

1) Role & Responsibilities of a QC Engineer?

 Shall be well aware of the Project Quality Requirements, Standards and Contract
Specifications and Drawings
 To prepare the Quality Plan, Procedures, ITP’s, WPS’s and other documents related to
the Project
 Review of MTC and perform Material Inspection and offering the same to client

 Conduct PQR and Welder tests in presence of Client

 Monitoring Fabrication & Erection works, Welding and Welder performances at shop
and site as well
 Responsible for all the NDE activities carried out during the whole project

 Preparation of all Reports and Records and submission of the same to the client

 Preparation and submission of Inspection Notification to the client for all the activities

 Shall conduct Painter/Blaster qualification and perform Blasting and Painting inspections

 Conduct line walk down and listing out the punch items for the completion of the work

 Preparation of Hydrotest packages and Witnessing of Hydrotest

 Preparation of QC Dossier and submission to client for approval

2) What are all the activities involved during a project period (from start till end)?

 Design
 Preparation of Drawings, P&ID’s, GAD’s, Isometric’s, Weld Maps
 Preparation of Procedures, ITP’s, WPS, Method Statements
 PQR and Welder Test
 Fabrication & NDE works
 Shop Painting
 Erection & NDE works
 Base Line Thickness Measurement
 Pressure Test Packages
 Pressure Testing
 Field Painting
 QC Dossier

3)
4) What are all the things to be checked during a VPIM?

 The vendor testing facilities

 Vendor’s Quality system, Procedures and NDE methods
 Clarify all issues related to Quality, Inspection and Testing
 Finalize the Inspection and Test Plan
 Ensure the communication channels between Vendor, Contractor and the Company

5) How the documents of a Vendor are submitted to KNPC for approval?

The Documents are prepared by Vendor and submitted to Contractor for any
comments or issues. The contractor will review the document and ensure the
document relies with all the applicable standards, project and contract specifications.
The document will be marked up with all the comments and sent back to the vendor to
incorporate all the comments. Once the Contractor is satisfactory with the document
the same will be submitted to client for final approval. Any comments given by Client
will be given to the vendor through the contractor and the above steps will be
continued till the final approval of the document.

6) What are the variables in Welding? Explain briefly?

 Essential Variables – A change in welding condition which will affect the Mechanical
properties (other than Notch toughness) of a weldment.
(Eg., change in P no., welding process, filler metal, electrode, preheat or PWHT)
 Supplementary Essential Variables – A change in welding condition which will affect the
Notch toughness properties of a weldment.
(Eg., change in welding process, uphill or downhill, heat input, preheat or PWHT)
 Non Essential Variables – A change in welding condition which will not affect the
mechanical properties of a weldment.
(Eg., joint design, method of cleaning)

7) What are all the Mechanical tests done for a piping PQR?

 Tensile test
 Side bend test
 Face bend test
 Root bend test
 Impact test
 Macro examination

8) What are all the Mechanical tests done for a fillet welding?

 Fracture test
 Macro examination

9) What is Tensile strength and how the testing is done?

Tensile strength is defined as the maximum stress that a material can withstand before
fracturing or rupturing. The Tensile strength of a material can be determined by tensile
test. The strength is determined by employing the weld joint (butt weld) under a static
load. The test is performed by clamping the test piece at each end and a load is applied
by hydraulic means or screw mechanism. The load is increase until the fracture occurs.

10) After bend test and fracture test how the test piece is been examined or analyzed?

After bend or fracture test the specimen shall be examined for the location of fracture
and any flaws available on the fracture locations. If the fracture is in the parent metal
the distance from the weld zone shall be explained.

11) What is Toughness and what test is been done to measure it?

Toughness is defined as the energy absorbed by the body before fracturing or

rupturing. The toughness is measured by Charpy V Notch Impact test.

12) How the impact test has been carried out and by what method?

A machined and notched test specimen is broken by a pendulum with a single blow
and the energy absorbed is measured in Joules. The testing is done by Charpy impact
testing machine. After testing the specimen is examined for the fracture appearance
(brittle or ductile) and Lateral Expansion.

13) At what temperature the impact test has been carried out and for which materials?

The testing is done at room temperature. Testing at other than room temperatures is
mentioned in the product description, contract specification or as per the service
temperatures. Testing is normally done for steels. If it is done at low or high
temperatures the specimen shall be controlled in a media at the required temperature.

14) What is Lateral Expansion and how it is been analyzed?

 Lateral expansion is described as increase in width of the specimen of the compression
side opposite to that of the notch side of the fractured specimen. The amount of
expansion on each side of the notch or the point of maximum expansion on both the
sides, the sum of the larger values measured for each side is the value.

15) What is sensitivity in a radiographic film and how it should be maintained?

Sensitivity is a measure of level of response from a discontinuity i.e. even smallest

defects can be identified. The sensitivity of a radiographic film can be determined by
this formula. 2% of sensitivity shall be maintained throughout the film.

16) What is geometric unsharpness and how it shall be minimized?

Geometric unsharpness is a factor that affects the quality of the radiograph. The
Geometric unsharpness is a shadow in a radiograph which depends on the size of the
source, the distance between the source and the object and the distance between the
object and the film. It can be minimized by the distance maintained between the
source and the film. This can be calculated by using the formula

Ug = Fd/D

Where,

F = Source size

d = Distance between the object and the film

D = Distance between the source and the object

17) In what materials MPT cannot be done?

Magnetic particle testing cannot be done on non ferrous materials such as aluminum,
magnesium and stainless steel. MPT over the painted surface will not give the desired
inspection sensitivity hence the coating shall be removed.

18) In which NDT methods sub surface defects can be found out?

Sub Surface defects can be found by RT, UT and MPT methods.

19) In MPT method sub surface defects can be detected by using which current?

DC current

20) What is the min and max temperature for a LPT test to be done?
 The minimum and maximum temperature for the Liquid penetrant examination is 10 0C
and 500C.

21) What is the difference between 7018 and 7018-1 electrode?

7018 electrodes are used for carbon steel materials. 7018-1 electrodes are used for
Low temperature carbon steels. The major difference is the Impact testing done at
-450C for the 7018-1 electrodes.

22) What are all the types of coatings in an electrode?

The type of coatings in a electrode are i) Basic or Low hydrogen ii) Cellulose iii) Rutile

23) What are the difference between 6010 and 7018 electrode?

6010 are cellulose coated electrodes. 7018 are Basic or Low Hydrogen electrodes. 6010
is used for root welding in plate or pipes whereas 7018 is used for fill and capping
purpose since 7018 cannot be used for root welding as it will not give good penetration
in the root.

24) What is PMI and why it is done?

PMI is positive material identification. This is done to analyze the percentage of

alloying elements in a material.

25) In which type of PMI machine does carbon content can be detected?

There are portable type and spectrometer to perform PMI. In portable type the carbon
content cannot be detected whereas in spectrometer carbon% can be detected.
Portable machines are compact and can be used at any locations whereas
spectrometer type is difficult to use at sites.

26) Grove welding positions in plate and pipe? Testing and Qualifications in plate & pipe?

Grove welding positions in plate and pipes -

For testing and qualifications in Plate and Pipe

27) What is MEK solution and what is its purpose?

MEK (Methyl Ethyl Ketone) is a thinner like component used to check the curing of the
painting especially inorganic zinc silicate paints.

28) What are the parameters to be checked before starting the Painting works?

 Relative Humidity
 Surface temperature
 Wind speed
 Climatic conditions (Rain, Sand storm, Fog, drizzling, etc.)

29) What is the min and max temperature for painting to be carried out?

The painting shall not be carried out when the temperature is less than 3 0C above the
dew point or when the temperature is greater than 500C.

30) In what conditions painting shall not be carried out?

Painting shall not be carried out under adverse conditions such as Rain, Humidity greater
than 85%, sand storm, fog, temperature is less than 30C or greater than 500C etc.

31) What is the spec followed for valve testing? What are the types of test in valve
testing?

API 598

 Shell test – Required for Gate, Globe, Plug, Check, Floating Ball, Butterfly & Trunnion
mounted valves
 Back seat test – Required only for Gate & Globe Valves
 Low pressure closure test – Required for Floating Ball Valves. Optional for other valves
 High pressure closure test – Optional for Floating Ball Valves. Required for other valves

32) What are the contents of a hydrotest package?

 Pressure test certificate

 Pressurization monitoring report
 Gauge certificates
 Punch List
 Isometric index
 P&ID, GAD, Isometric, Weld map
 Weld inspection summary report
 NDE reports
 Pre hydrotest check list
 Reinstatement check list
 Flushing or Blowing report
33) What is L stands for in materials like 316L and 304L?

L is denoted for low carbon percentage. Normally 0.08% carbon will be available in SS
materials. When L is denoted the percentage is restricted up to 0.03%.

34) What is the difference between A106GrB and A333Gr6 and where it is being used?

A106 Gr B and A333 Gr 6 are piping materials. A106 is used for elevated temperature
service and A333 is used for low temperature service.

35) What are the types of welding joints?

 Butt joint
 Tee joint
 Corner joint
 Lap joint

36) How to calculate Heat Input?

Heat input can be calculated by the formula

37) What is the Inter pass temperature for stainless steel welding?

Interpass temperature for Stainless steel is 1750C Max.